Inlaid paving unit

ABSTRACT

An inlaid paver and method for making an inlaid paver is disclosed. A paving unit with a first surface and a second surface is provided. The inlaid paver has a hole in the first surface of the paving unit and has a depth extending to a second surface of the paving unit. The inlaid paver has an inlay unit fitted to the hole. The hole may be formed using a water jet.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to the field of paving units. In particular the invention relates to providing a paving unit with a hole passing through a paver for fitting an object, such as a second paving unit.

2. Description of the Related Technology

Masonry paving units, usually made out of concrete, clay, asphalt, and other materials are commonly referred to as pavers. Pavers are used for city streetscape projects, commercial plazas, residential driveways, sidewalks, fountains, memorials, roof decks and patios. Interlocking pavers are typically made from cement and aggregates, and may support loads greater than 8,000 psi. Using interlocking pavers provides a sturdy walking surface with no long runs of large seams, which is required for a poured concrete surface. The vertical faces of adjacent pavers provide support for each other when laid. Pavers are typically laid on a screed sand base overlaying a compacted aggregate base. Laying pavers on this type of base provides a load-equalizing surface and assists in water drainage. Each paver has the ability to move slightly in a vertical direction without significantly tilting the paver when a pressure is applied to the surface of the paver, such as when a vehicle drives across the paver. This flexibility permits the pressure load to be shared between pavers, as contrasted with a poured concrete pavement, which may crack rather than move.

Interlocking pavers have many advantages when compared to poured concrete. Hot and dry climates are not suitable for proper curing of concrete pavements that are poured in place. Concrete paved spaces in these areas may have improperly-cured surfaces and interior voids that cause the concrete to crack and wear rapidly. In contrast, pavers, are typically cast in a controlled environment and when installed can provide up to three times the strength of concrete poured in the same area. Pavers also provide better water drainage and a greater resistance to freeze-thaw cracking in cold climates.

Typically a paver can be made by creating a mold to form the paver. The mold can be used to create a variety of shapes. However, for more complicated designs a paver is usually cut and shaped by hand and not simply molded to that shape. This is a time consuming and involved process. Furthermore, the molding process limits the creation of intricate designs and patterns due to the typical paver that is made during the molding process. The typical paver that is made during this process is a simple rectangle or square. Occasionally other geometric shapes may be made as well, such as octagons, however this tends to be the extent of the creativity found in the paver industry. When laying pavers a person has to then cut the pre-formed pavers into specific designs in order to achieve an artistic effect. This is a time-consuming and costly process and generally leaves additional seams that may spoil the intended artistic effect.

Another design feature of pavers is inlays, or inserts. Inlays are design features that are traditionally placed on the surface area of the paver unit. An inlay is an aesthetically pleasing artistic element, however it may lack the durability of a full paver unit since it typically extends only a limited distance within the paver, and does not assist in providing overall structural integrity to the paving structure. Furthermore, to provide a design feature within the interior surface area of a paver is a complicated process and requires time consuming manual cutting involving grinding, sawing and drilling. Additionally, inlays, or inserts may be easily dislodged or intentionally removed from their shallow cavities. This can spoil the desired effect of the paver surface and can increase the cost of maintaining the paver surface.

Conventionally, to place an inlay within a paver so that the inlay stretches throughout the depth of the paver requires the paver units to be cut along the length and width of the paving units, and then using the cut pieces to build around the inlay. This weakens the structural integrity of the paving unit and further mars the desired aesthetic effect of having an inlay placed within the interior of the paver by creating additional seams.

Currently, no paver provides a strong and durable inlay within the interior of the paver. Therefore, there exists a need for providing a cost-effective method for creating pavers with an inlay that extends the entire depth of a paver in order to provide a durable design feature as well as enhancing the aesthetic appeal of the paver.

SUMMARY OF THE INVENTION

According to a first aspect of the invention, a method for forming an inlaid paver is provided. The method includes providing a paver unit having a first surface and a second surface. Forming a hole in a paver unit extending from the first surface of the paver unit to the second surface of the paver unit and then fitting an inlay unit within the hole formed in the paver unit.

According to a second aspect of the invention, a method for forming a composite paver is provided. The method includes providing a paver unit having a first surface and a second surface. Forming a hole extending from the first surface of the paver unit to the second surface of the paver unit using a water jet to form a hole in the paver unit and then fitting an object within the hole.

According to a third aspect of the invention, an inlaid paver having a paving unit with a first surface and a second surface is provided. The inlaid paver has a hole in the first surface of the paving unit, with the hole having a depth extending to the second surface of the paving unit. The inlaid paver has an inlay unit fitted to the hole. The inlay unit has a first and second surface.

These and various other advantages and features of novelty that characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and the objects obtained by its use, reference should be made to the drawings which form a further part hereof, and to the accompanying descriptive matter, in which there is illustrated and described a preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart depicting a method for forming an inlaid paver.

FIG. 2 is a top down view of an inlaid paver looking down at top surface.

FIG. 3 is an isometric view of an inlay unit and paver unit.

FIG. 4 is a top down view of an inlaid paver looking down at bottom surface.

FIG. 5 is a top down view of an inlaid paver with two inlay units.

FIG. 6 is an isometric view of an inlaid paver with an illumination device.

FIG. 7 is an isometric view of inlaid paver with a textured surface.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Pavers have a variety of applications in the construction field. Pavers can be utilized for city streetscape projects, commercial plazas, residential driveways, sidewalks, fountains, memorials, roof decks and patios. Pavers also provide an aesthetically appealing element to functional construction projects, such as pathways. Inlaid pavers with an ornamental structure that extends the depth of the paver unit provide both a useful advantage and a design advantage over existing pavers.

Referring now to the drawings, wherein like reference numerals designate corresponding structure throughout the views, and referring now to FIG. 1, wherein the method of forming an inlaid paver is shown.

As shown in FIG. 1, showing the method, at step 102 a paver unit 2, shown in FIG. 2, is provided. Paver unit 2 is made of paver material, which typically consists of concrete, clay, asphalt, or other natural stone materials. Preferably, the material used for fabricating paver unit 2 is Portland Cement Type 1 combined with aggregate (crushed stone). Paver units 2 can come in various shapes, sizes and colors. Colored paver units 2 are typically not painted, but are produced through a special pigmentation process that provides color through the top wear layer of the paver, which is usually from a ¼ inch to ½ inch. Traditional paver sizes can include 4 inches by 8 inches, 6 inches by 9 inches, and 6 inches by 6 inches. Non-standard sizes can be 12 inch by 12 inch to 16 inch by 16 inch. For non-vehicular applications a paver of roughly 2⅜ inches can be used, while for construction where heavy traffic passes, pavers can be roughly 3⅛ inches thick. Preferably, finished inlaid paver 10, shown in FIG. 2, will have a minimum compressive strength of 8,000 PSI and a maximum absorption of 5%. Aggregates used for laying the interlocking inlaid pavers 10 are preferably washed, graded sand and limestone, however expanded shale and lightweight aggregate may be used.

At step 104 a hole 4, shown in FIG. 3 is formed in paver unit 2. This hole is preferably created by using abrasive water jet cutting technology. Hole 4 extends from top surface 7, shown in FIGS. 2 and 3 to bottom surface 9, shown in FIG. 4. Using a water jet provides better control during the cutting process and permits a more precise cut to be made. Alternatively, it would be possible to create a mold that would create a paver with the desired characteristics. However, it may be more efficient, and more flexible for creating design options to utilize existing pavers and use the water jet to form the desired shape and corresponding inlay unit 6, shown in FIG. 2.

At step 106 an inlay unit 6, as shown in FIGS. 2-4 is cut. A plurality of pavers units 2 consisting of two separate materials, or having separate colors can be placed into two groups. An inlay unit 6 can be cut out of one of the two groups of pavers units 2, thereby creating an inlay unit 6 and a paver unit 2 consisting of one type of material or having one color. In the other group of pavers units 2 an inlay unit 6 and a paver unit 2 may be formed. Inlay units 6 formed from one group may be used with the paver units 2 formed from the other group. This will save time and material. This can also enable a higher level of customization than mass-producing molded blocks.

At step 108 the inlay unit 6, as shown in FIGS. 2-4, is inserted into hole 4, shown in FIG. 3. Inlay unit 6 has a height that is substantially as great as the depth of hole 4, but preferably as great as the depth of hole 4, so that inlay unit 6 extends the depth of paver unit 2.

FIG. 2 shows a top down view of inlaid paver 10. Inlaid paver 10 is constructed of paving unit 2 and inlay unit 6. Paving unit 2 has a hole 4 cut out of it by a water jet in the interior of top surface 7. In the example shown in FIG. 2, paver unit 2 is rectangular in shape, however paver unit 2 may be shaped in other patterns, or may be specially designed to form a desired shape. Hole 4, shown in FIG. 3, is typically sized so that inlay unit 6 can be fitted into paver unit 2. Hole 4 passes completely through paving unit 2 in the z direction. The depth of hole 4, which is measured in the z direction is substantially equal to the height of inlay unit 6, which is measured in the z direction. Having inlay unit 6 fitted to hole 4 enables inlay unit 6 to be stable structurally as well as providing a smooth walking or driving surface. This also provides a smooth base, which enables a high degree of structural integrity. Inlay unit 6 has a top surface 11 that is preferably planar with top surface 7 of paver unit 2 when it is placed within hole 4. In addition to providing a smooth base for laying and a smooth surface for walking or driving, having inlay unit 6 extend the depth of hole 4 also enables inlay unit 6 to maintain an interlocking effect within paver unit 2. This is advantageous over typical inlays, which can easily be removed or dislodged. The interlocking effect enables inlay unit 6 to compensate for vertical, horizontal, and rotational forces that affect pavers during their usage, thereby preventing accidental dislodgement.

As shown in FIG. 3, inlay unit 6 has a diamond shape, although it is to be understood that a diamond shape is used for example purposes and that the shape of the inlay unit may vary. Hole 4 has a diamond shape that corresponds to the diamond shape of inlay unit 6. Alternatively, hole 4 formed in paver unit 2 can be of a variety of shapes and designs, such as a flower, a leaf, geometric figures, symbols, letters, numbers, and waves, also corresponding to a similar shape of inlay unit 6. It may be possible to create a design that would place a non conforming shape in a suitable sized hole 4, such as a rectangular shaped inlay unit 6, placed in a circular hole 4, or alternatively have an additional inlay design placed on inlay unit 6 thereby increasing the complexity of the overall design. Using two differently colored inlay units 6 to form the interior design may be used to create additional designs, such as a yin-yang. Additionally, a plurality of inlaid paver units 10 may be used to create a tessellation, or a complicated design pattern.

Placing inlay unit 6 in the interior of top surface 7 within hole 4 provides an advantage in design by enabling a border to be laid around a pathway without being concerned with matching design features of paver unit 2. In conventional pavers, design features have to be specially cut in order to match designs when laying borders in an arc formation. Since inlay unit 6 is within the interior of top surface 7, in the pre-fabricated inlay pavers 10, instead of being a separate feature to be cut while laying a border, it is easier to lay an ornamental paver border in areas that would have previously been difficult due to the complexity in aligning certain design patterns. This also permits a border to be laid in a more efficient fashion than standard pavers since the amount of cuts needed while laying a border can be reduced. Standard pavers require additionally cutting when laying a border in order to align the various design features.

Inlay unit 6 may be made from another paver cut to fit into hole 4. Alternatively, inlay unit 6 may also be constructed of a metallic material such as pewter, brass, etc.

FIG. 4 shows a top down view of inlay paver 10 looking at bottom surface 9 of paver unit 2. Bottom surface 13 of inlay unit 6 forms a substantially planar surface with bottom surface 9 of paver unit 2 when inlay unit 6 is fitted in hole 4. This provides a stable paver for construction purposes by providing a smooth base.

FIG. 5 shows a top down view of inlaid paver 10 that has a first inlay unit 6 and a second inlay unit 14 placed in paver unit 2. Alternative embodiments may have more than two inlay units 6, and 14. Inlay unit 6 may be constructed of different material or the same material as inlay unit 14. Inlay units 6 and 14 may be different colors in order to provide various design features.

As shown in FIG. 6, inlaid paver 10 is constructed with paver unit 2 and an inlay unit that is an illumination unit 8 sized to fit within a hole provided in paver unit 2. Illumination unit 8 may be constructed in a variety of shapes and sizes depending on the desired effect. Illumination unit 8 can be an illumination device, such as an electrical fixture or solar panel. In a preferred embodiment it is a chamber filled with tritium gas, or another self-contained illuminating gas. Tritium gas provides illumination due to its radioactive nature. This provides a self-contained source of illumination without requiring electrical wiring. Without the need for electrical wiring inlaid paver 10 can be placed in areas that otherwise would be difficult to electrically wire.

As shown in FIG. 7, inlaid paver 10 is constructed with paver unit 2 and textured unit 12 sized to fit within a hole provided in paver unit 2. Textured unit 12 can be brightly colored, textured, and made in a variety of shapes, thereby making the inlaid paver 10 suitable for usage in safety areas. Textured unit 12 could also be made of rubber, or some other material that would provide an additional tactile difference between paver unit 2 and textured unit 12. Textured unit 12 can be used in inlaid pavers 10 placed along the borders of train and subway tracks, and along the curbs of streets. The textured surface provides indication to blind people that a dangerous situation is ahead. Having the surface brightly colored can also provide warnings to people.

Alternative embodiments of inlaid paver 10 can use hole 4 as a means for securing fence posts, or other structures. Hole 4 can be sized to secure a fence post without detracting from the overall design of the paver construction. Inlaid paver 10 can also house a variety of electrical components, such as components for security systems, or components for electric dog fences. By housing components such as these in the inlaid paver 10 it is possible to provide both a highly functional construction as well as an aesthetically pleasing one. In a scenario where a dog fence component, or security sensor is provided in inlaid paver 10, these inlaid pavers 10 can then be arranged along the perimeter of the area that needs to be protected.

It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

1. A method for forming an inlaid paver comprising: providing a paver unit having a first surface and a second surface; forming a hole in said paver unit extending from said first surface of the paver unit to said second surface of the paver unit; and fitting an object within said hole formed in said paver unit.
 2. The method of claim 1, wherein said step of forming a hole is performed using a water jet.
 3. The method of claim 1, wherein said step of forming a hole is performed using a mold.
 4. The method of claim 24, wherein said inlay unit has substantially the same contour as said hole and substantially the same height as a depth of said hole.
 5. The method of claim 24, wherein said inlay unit is diamond shaped.
 6. The method of claim 24, wherein said inlay unit has a roughened surface.
 7. The method claim 24, wherein said inlay unit is constructed of a metallic material.
 8. The method of claim 24, wherein said inlay unit is constructed of a paver material.
 9. The method of claim 24, further comprising forming a second hole in said paver unit and fitting a second inlay unit in said second hole.
 10. (canceled)
 11. The method of claim 2, wherein said object fitted within said hole is an illumination device.
 12. The method of claim 11, wherein said illumination device uses tritium gas.
 13. The method of claim 2, wherein said object fitted within said hole is a post.
 14. The method of claim 2, wherein said object fitted within said hole is an electronic device.
 15. The method of claim 2, wherein said object fitted within said hole has different textures.
 16. An inlaid paver comprising: a paving unit having a first surface and a second surface; a hole in said first surface of the paving unit having a depth extending to said second surface of the paving unit; an inlay unit fitted to said hole, said inlay unit having a first surface and a second surface.
 17. The inlaid paver of claim 16, wherein said first surface of said inlay unit and said first surface of said paving unit form a substantially planar surface when said inlay unit is fitted to said hole, and said second surface of said inlay unit and said second surface of said paving unit form a substantially planar surface when said inlay unit is fitted to said hole.
 18. The inlaid paver of claim 17, wherein said inlay unit is diamond shaped.
 19. The inlaid paver of claim 17, wherein said first surface of said inlay unit is roughened.
 20. The inlaid paver of claim 17, wherein said inlay unit is constructed of a metallic material.
 21. The inlaid paver of claim 17, wherein said inlay unit is constructed of paver material.
 22. The inlaid paver of claim 17, wherein said inlay unit is an illumination device.
 23. The inlaid paver of claim 22, wherein said inlay unit is an illumination device using tritium gas.
 24. The method of claim 1, wherein said object is an inlay unit. 